From increased weight savings and faster product development cycles to lower costs and better repair options, Eaton’s advancements in additive manufacturing are paving the way for performance breakthroughs on current and next-generation aircraft.

“Eaton continues ramping up additive manufacturing of both metal and polymeric components based on the value these processes are creating for our customers,” said Dave Bailey, vice president, Technology, Eaton. “Our additive manufacturing teams are pushing the design limits of what is possible in aircraft applications, with a goal to quickly and cost effectively develop new products to meet the evolving needs of the aerospace industry.”

Most of the industry’s developments in additive manufacturing (also known as 3D printing) have involved high-cost materials such as cobalt, chrome, titanium and Inconel. By investing in processes using aluminum and other less expensive materials, Eaton is enhancing the speed, cost and system performance benefits of its additive technologies. Eaton also is producing lighter components. For single-aisle aircraft, aluminum can save hundreds of pounds per airplane for a typical component ship set. Eaton has already signed production contracts with military and commercial customers for aluminum additive manufactured parts.

A deep knowledge of material science enables Eaton’s team to rapidly qualify material choices, and their expertise in additive processes and component design supports rapid prototyping. Results include shorter development and manufacturing lead times, faster speed to market, lower manufacturing costs and improved product performance.

Eaton’s innovative redesign of its ram air valve assembly is a great example of the benefits and capabilities of additive manufacturing. Not only did Eaton’s additive solution reduce development time for two critical parts by 75 percent, but it also reduced part weight by 10 percent. In addition, Eaton decreased assembly time and eliminated potential leak paths such as seals and threaded joints by consolidating 22 parts into a single printed part.

Eaton plans to produce ram air valve assemblies at its AS9100-certified Additive Manufacturing Center of Excellence (COE) in Southfield, Michigan. Eaton also operates an Additive Manufacturing COE in Pune, India.

Eaton’s centers are one-stop shops with capabilities to design, manufacture, inspect, assemble and ship the next generation of aerospace components. Eaton also is using additive processes to improve repair options for aftermarket customers, such as cold spray technology to repair older and more unique parts.